Electrodes for and methods of electrical discharge machining

Abstract

Electrodes for and methods of electrical discharge machining are provided. For example, a method for forming a feature in a ceramic matrix composite (CMC) component comprises repeatedly advancing an electrode into and retracting the electrode from the CMC component until a desired depth is reached, where the electrode has a head end, a tip end, and a shaft extending from the head end to the tip end. The shaft has a first side and a second side each recessed inward such that the head end and the tip end are wider than the shaft. A method for forming a feature in a CMC component also may include feeding a dielectric fluid into the feature utilizing the recessed sides. In some embodiments, electrodes may include a shaft extending from a head end to a tip end and a central plane, where the shaft is recessed widthwise toward the central plane.

What is claimed is: 
     
       1. An electrode for electrical discharge machining, the electrode defining a length direction, a width direction, and a height direction, the electrode comprising:
 a head end; 
 a tip end; 
 a shaft extending from the head end to the tip end; and 
 a central plane defined through the head end, shaft, and tip end, 
 wherein the shaft is recessed along the width direction toward the central plane such that both the head end and the tip end are wider than the shaft, and 
 wherein the electrode is configured to discharge electricity to machine a component and 
 wherein the tip end has a height, and wherein the ratio of the height of the tip end to a slot depth for the component is within a range of 0.05 to 0.5. 
 
     
     
       2. The electrode as in  claim 1 , wherein the shaft has a first side and a second side, and wherein the first side is recessed along the width direction toward the central plane. 
     
     
       3. The electrode of  claim 2 , wherein the second side is recessed along the width direction toward the central plane. 
     
     
       4. The electrode of  claim 1 , wherein the shaft has a first side and a second side, and wherein a plurality of apertures is defined through the shaft from the first side to the second side. 
     
     
       5. The electrode of  claim 1 , further comprising an insulation material on an outer surface of the shaft. 
     
     
       6. The electrode of  claim 5 , wherein the shaft has a first side and a second side, and wherein a plurality of apertures are defined through the insulation material and the shaft, the plurality of apertures defined from the first side to the second side. 
     
     
       7. The electrode of  claim 1 , wherein the shaft has an outer surface, and wherein the shaft includes a plurality of fins along the outer surface. 
     
     
       8. The electrode of  claim 1 , wherein the shaft has an outer surface, and wherein a plurality of grooves is defined in the outer surface of the shaft. 
     
     
       9. The electrode of  claim 1 , wherein the shaft has an outer surface, and wherein a plurality of abrasive pads is defined on the outer surface of the shaft. 
     
     
       10. The electrode of  claim 1 , wherein the tip end has a height, the height of the tip end selected to optimize a cutting speed of the electrode. 
     
     
       11. An electrode for electrical discharge machining, the electrode defining a length direction, a width direction, and a height direction, the electrode comprising:
 a head end; 
 a tip end; 
 a shaft extending from the head end to the tip end; 
 an insulation material on an outer surface of the shaft; and 
 a central plane defined through the head end, shaft, and tip end, 
 wherein the shaft is recessed along the width direction toward the central plane, 
 wherein the shaft has a first side and a second side, and 
 wherein a plurality of apertures are defined through the insulation material and the shaft, the plurality of apertures defined from the first side to the second side.